Siding System with Joint and Siding Support

ABSTRACT

The claims relate to a siding system for industrial, commercial or residential construction including a siding member and member support.

FIELD

The subject matter relates to an external finish siding system for commercial, industrial and residential construction. The system provides an easily installed attractive exterior appearance.

BACKGROUND

Many materials have been used as an exterior on residential, commercial and industrial structures. Initially, brick, stucco, wood siding were popular choices. Traditional wood siding in a clapboard or shake is characterized by a tapered shape from a rather thick base portion to a rather thin upper edge. This design permits the siding to be nailed to the studs or other framing components of the house in overlapping relationship, in which the lower edge of each course overlaps the upper edge of the next lower course so as to shed rain. This design is an accepted engineering and design choice. All of these conventional siding options, while being useful and attractive, poses challenges in installation, weathering and requires periodic maintenance. This type of siding may also experience uneven weathering for unfinished surfaces, and tends to split, cup, check or warp.

To avoid these problems, newer materials have been developed, and has enjoyed a widespread acceptance nationwide. Aluminum, composite hardboard, composite concrete, plywood and vinyl recently have come to dominate the siding market. These materials simulate design and appearance of conventional and popular clapboard, shakes and shingles, but have improved weathering properties. The materials, shapes and textures of these materials produce highlights and shadow lines on walk as the sun shifts in position during daylight similar to more conventional materials.

Aluminum siding is normally made by a roll forming process and is factory painted or enameled to require substantially no maintenance during the life of the installation. However, metal siding tends to be energy inefficient and may transfer substantial quantities of heat. Vinyl siding can be extruded in a continuous fashion or molded, after which lengths are cut to the desired length. Siding of this nature can be pigmented so as to be extruded or molded in the requisite color, thus avoiding the need for painting. However, vinyl lacks mechanical integrity and is difficult for the home owner to refinish in a different color. While aluminum and vinyl sidings have obvious advantages, such as a preformed surface finish and the elimination of maintenance, these siding choices pose certain known and inherent disadvantages.

Vinyl polymer materials have been combined with fibers to make extruded materials. Most commonly, polyvinyl chloride, polystyrene, and polyethylene thermoplastics have been used in such products. Such materials have successfully been used in the form of a structural member that is a direct replacement for wood. These extruded materials have sufficient modulus, compressive strength, coefficient of thermal expansion to match wood to produce a direct replacement material. Typical composite materials have achieved a modulus greater than about 500,000 and greater than 800,000 psi, an acceptable COTE, tensile strength, compressive strength, etc. Deaner et al., U.S. Pat. Nos. 5,406,768 and 5,441,801, U.S. Ser. Nos. 08/224,396, 08/224,399, 08/326,472, 08/326,479, 08/326,480, 08/372,101 and 08/326,481 disclose a PVC/wood fiber composite that can be used as a high strength material in a structural member. This PVC/fiber composite has utility in many window and door applications, as well as many other applications, Hendrickson U.S. Pat. Nos. 6,122,877 and 6,682,814 disclose composite siding systems.

Accordingly, a substantial need exists for the development of a siding formed from a suitable composite material which can be directly formed into reproducible, stable shapes that are advantageous for installation and use as siding members. The siding structure must have resistance to weathering, relatively high strength and stiffness, an acceptable coefficient of thermal expansion, low thermal transmission, resistance to insect attack and rot, and a hardness and rigidity that permits sawing, milling, and fastening characteristics. The material must be able to be easily installed and maintained. The material must maintain stable dimensions after installation, while having the ability to be painted, cut, milled, drilled and fastened at least as well as wooden materials.

BRIEF DESCRIPTION

The siding system design has an appearance similar to wood and other conventional clapboards and is a system that permits the siding to be efficiently installed on a rough exterior, studs or other framing components. The system is installed in overlapping relationship, in which the lower edge of each course overlaps the upper edge of the next lower course so as to shed rain and maintain a pleasing appearance. The siding system is configured for ease of installation and is made of environmentally stable materials.

This design has two embodiments, both embodiments have, in common, a J-form drip edge in an upper course that can be inserted into to a cooperating channel in a lower course for installation.

In a first embodiment a siding member is installed on a rough surface using a butt joint support and a corner joint support. In this aspect, the siding courses, installed on the supports are maintained by joining the course using an installation channel that is joined to a J-form joint. A nailing flange comprises an attachment locus for the siding portion and a J-shaped connection adapted to an adjacent siding member. The siding portion comprises a J-shaped connection adapted to connection to the nailing flange. Each of the butt joint support and the corner support comprises a tapered adhesive joint surface for positioning, supporting and installing the siding.

In a second embodiment, a unitary siding member includes both a support and installation using the cooperating installation channel and J-form joint. The courses are supported by supports integrated into the siding member. The system is installed by joining one siding member to another using the interaction of the installation channel and the J-form edge. The angle of the siding is maintained by the integral support.

The above summary is not intended to describe each disclosed embodiment or every implementation of the siding technology. The description that follows more particularly exemplifies illustrative embodiments. In several places throughout the application, guidance is provided through lists of Figures and Figure elements that can be used in various combinations. In each instance, the recited list serves only as representative grouping and should not be interpreted as an exclusive list.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

Useful in Embodiment 1

FIGS. 1 and 3 are a plan view of the obverse and reverse view of the butt joint support and adhesive attachment for the siding member;

FIGS. 2 and 4 are a plan view of the obverse and reverse view of the corner joint support and adhesive attachment;

FIG. 5 is a plan view of the butt joint support and adhesive attachment supporting the siding member;

FIG. 6 is an isometric view of the corner joint support and adhesive attachment supporting the siding member;

FIG. 7 is a side view of the butt joint support and adhesive attachment surface for the siding member (not shown);

FIG. 8 is a side view of the corner joint support and adhesive attachment for the siding member (not shown);

FIG. 9 is an isometric view of the siding member and its installation nailing flange;

Useful in Embodiment 1 and 2

FIG. 10 is a side view that shows the orientation of two of the installed siding members.

FIG. 11 is a side view that shows a detail of FIG. 10 with the interaction of the nailing flange joinery channel aspect and the J-form joinery aspect.

FIG. 12 is a side view that shows the installation adhesive on the corner joint support.

Useful in Embodiment 2

FIG. 13 shows a siding member aspect that can be nailed but has no dedicated fastener aperture in the nailing flange.

FIG. 14 shows detail of an installation support and installation channel.

FIG. 15 shows a side view of an installation of two courses of a siding aspect.

FIG. 16 shows a plan view of an installation of the siding member 130 with the installation support 140.

The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

DETAILED DISCUSSION

The siding system comprises a siding member and associated installation components and supports. A successful system requires a mechanically stable assembly of components, and a set of interacting elements that permit quick and permanent installation of the siding member. The system requires a support system that holds the siding member is the correct orientation such that the appearance is aesthetically appealing and sheds water at a drip line. The minimum components include (1) an embodiment with a cooperating set of a J-form drip edge that can be inserted into an installation channel and (2) an embodiment that can support or supports the position of the siding member in the correct installation orientation. These components can be integrated into the siding member or can be individually manufactured and installed. In installation of the system, either embodiment 1 or 2, a first or starter course is installed. The starter course must contain at least a siding member component and an installation channel. After installation of the first course (using a series of siding members) using an appropriate fastener, the J-form edge of the second course units are inserted into the installation channel and fixed in place. The third course follows in turn. In embodiment 1, the siding orientation is maintained by the butt joint and corner joint supports. In embodiment 2 the siding orientation is maintained by the integral supports.

The system can be installed onto any conventional rough building component or surface using associated fasteners. Examples include particle board, OSB, plywood, wooden framing, steel framing, plastic sheeting, house wrap, moisture barrier, etc.

The system components can be made of polymer or composite. In large part the siding member is composite, but minor elements (flanges, etc.) can be polymer materials. A useful composite is made by combining an interfacial modified fiber and a polymer to achieve novel physical and process properties. The fiber is typically coated with an interfacial surface chemical treatment also called an interfacial modifier (IM) that supports or enhances the final properties of the composite such as viscoelasticity, rheology, high packing fraction, and fiber surface inertness. These properties are not present in contemporary composite materials.

In embodiment 1 the system includes a siding member with J-form edge and installation channel that can be installed with butt joint and corner joint support structures. In embodiment 2, the system includes a siding member that has a siding member, cooperating J-form edge with installation channel and support structure in an integrated unit.

The siding member requires at least an exposed decorative surface, a J-form drip edge, a nailing flange and a channel the can be used in cooperation with the J-form edge to install the siding member in repeating courses. The J-form edge and the installation channel are formed on opposite edges of the siding. The nailing flange can be formed with fastener apertures or can be left with no perforations. The member can be made (extruded) in a unitary part or can be assembled from two or more elements. The revealed surface can be flat, textured, uncolored or can be colored with dye or pigment in the composite or in a capstock layer on the composite. This surface can be painted as needed. The nailing flange can be made (extruded) separately from the siding and can be joined to the siding with conventional joinery. The nailing flange can contain the installation channel and a support structure.

The butt joint and corner joint supports can contain a nailing flange and a tapered support component. These can be made separately or can be made as an integrated unit. The butt joint support flange is substantially planar, and the corner support has two planar members that are joined at a site that contains an angle β that is complementary to the angle of the rough exterior corner, but is typically 90°±5°. The butt joint and corner joint supports can contain a tapered support that is configured to maintain the siding at the conventional orientation for aesthetics and water shedding character. The degree of taper increases from the top to the bottom of the support at an angle α (typically less than 10°). The support can be formed in one two or more embodiments and can wrap the corner. The support has a support surface that is substantially planar and is configured to match and support the profile of the siding member. The support can have an adhesive layer to fix the siding in place. The adhesive can be applied during installation or can be applied during manufacture. One useful adhesive is an adhesive mass and release liner that can be applied from a roll during manufacture. The supports are installed to the rough surface with conventional fasteners using fastener apertures if needed.

In embodiment 1, the system is installed by placing corner joint supports on opposite corners of a rough surface. Between the corners are placed the butt joints supports is sufficient numbers to support the siding. A first course is then partially or fully installed on the supports using adhesive. A second course is than started similarly with the corner and butt joint supports. The J-form drip edge of the second course is inserted into the installation channel of the first to make a mechanically stable installation.

The composite used to make the siding member is more than a simple admixture. A composite is defined as a combination of two or more substances at various percentages, in which each component results in properties that are in addition to or superior to those of its constituents. In a simple admixture the mixed material has little interaction and little property enhancement. At least one of the materials in the composite is chosen to increase stiffness, strength or density. The atoms and molecules in the components of the composite can form bonds with other atoms or molecules using a number of mechanisms. Such bonding can occur between the electron cloud of an atom or molecular surfaces including molecular-molecular interactions, atom-molecular interactions and atom-atom interactions. Each bonding mechanism involves characteristic forces and dimensions between the atomic centers even in molecular interactions.

An interfacial modifier (IM) is an organo-metallic material that provides an exterior coating on the fiber promoting the close particle to particle association, packing and friction reduction. No particle to particle or particle to polymer attachment or bonding is formed. The composite properties arise from the intimate association of the polymer and fiber obtained by use of careful processing and manufacture. The lack of reactive bonding between the components of the composite leads to the formation of the novel composite—such as high packing fraction, commercially useful rheology, viscoelastic properties, and surface inertness of the fiber. These characteristics can be readily observed when the composite with interfacially modified coated fiber is compared to fiber lacking the interfacial modifier coating. In one embodiment, the coating of interfacial modifier at least partially covers the surface of the fiber. In another embodiment, the coating of interfacial modifier continuously and uniformly covers the surface of the fiber, in a continuous coating phase layer. Minimal amounts of the modifier can be used including about 0.005 to 8 wt.-%, about 0.02 to 6.0, wt. %, about 0.02 to 3.0 wt. %, about 0.02 to 4.0 wt. % or about 0.02 to 5.0 wt. %, the percentages based on the weigh to the coated particulate od fiber. The IM coating can be formed as a coating of at least 3 molecular layers or at least about 50 or about 100 to 500 or about 100 to 1000 angstroms (Å). The claimed composites with increased loadings of fiber can be safely compounded and thermoplastically formed into the high strength siding members.

Interfacial modifiers used in the application fall into broad categories including, for example, titanate compounds, zirconate compounds, hafnium compounds, samarium compounds, strontium compounds, neodymium compounds, yttrium compounds, phosphonate compounds, aluminate compounds and zinc compounds. Aluminates, phosphonates, titanate and zirconate that are useful contain from about 1 to about 3 ligands comprising hydrocarbyl phosphate esters and/or hydrocarbyl sulfonate esters and about 1 to 3 hydrocarbyl ligands which may further contain unsaturation and heteroatoms such as oxygen, nitrogen and sulfur. In embodiments the titanate and zirconate contain from about 2 to about 3 ligands comprising hydrocarbyl phosphate esters and/or hydrocarbyl sulfonate esters, preferably 3 of such ligands and about 1 to 2 hydrocarbyl ligands, preferably 1 hydrocarbyl ligand. Mixtures of the organo-metallic materials may be used.

The interfacial modification technology depends on the ability to isolate the particles or fibers from the continuous polymer phase. The isolation is obtained from a continuous molecular layer(s) of interfacial modifier to be distributed over the surface. Once this layer is applied, the behavior at the interface of the interfacial modifier to polymer dominates and defines the physical properties of the composite and the shaped or structural article (e.g. modulus, tensile, rheology, packing fraction and elongation behavior) while the bulk nature of the fiber dominates the bulk material characteristics of the composite (e.g. density, thermal conductivity, compressive strength). The correlation of fiber bulk properties to that of the final composite is especially strong due to the high-volume percentage loadings of discontinuous phase, such as fiber, associated with the technology.

Sizing or other coating materials used as glass coatings do not act as interfacial modifiers. Sizing is an essential processing component in glass fiber manufacture. Sizing is critical to certain glass fiber characteristics determining how fibers will be handled during manufacturing and use. Raw fibers are abrasive and easily abraded and reduced in size. Without sizing, fibers can be reduced to useless “fuzz” during processing. Sizing formulations have been used by manufacturers to distinguish their glass products from competitors' glass products. Glass fiber sizing, typically, is a mixture of several chemistries each contributing to sizing performance on the glass fiber surface. Sizings typically are manufactured from film forming compositions and reactive coupling agents. Once formed, the combination of a film forming material and a reactive coupler forms a reactively coupled film that is, reactively coupled to the glass fiber surface. The sizing protects the fiber, holding fibers together prior to molding but promote dispersion of the fiber when encountering polymer or resin thus insuring wet out of glass fiber with resin during composite manufacture. Typically, the coupling agent used with the film forming agent, is a reactive alkoxy silane compound serving primarily to bond the glass fiber to their matrix or film forming resin. Silane typically have a silicon containing group and that bonds well to glass (typically SiO₂) with a reactive organic end that bonds well to film forming polymer resins. Sizings also may contain additional lubricating agents as well as anti-static agents. We have used sized fibers in our studies and found that sizing does not act as interfacial modifier or interfere with the IM and we can coat all sizing materials that we have found with an IM with no loss of performance of the composite.

Useful fiber includes both natural and synthetic fibers. Natural fiber includes those of animal or plant origin. Plant based examples include cellulosic materials such as wood fiber, cotton, flax, jute, cellulose acetate etc.; animal based materials made of protein include wool, silk etc. Synthetic fibers include polymer materials such as acrylic, aramid, amide-imide, nylon, polyolefin, polyester, polyurethane, carbon, etc. Other types include glass, metal, or ceramic fibers. Metallic fibers are manufactured fibers of metal, metal coated plastic or a core completely covered by metal. Non-limiting examples of such metal fibers include gold, silver, aluminum, stainless steel and copper. The metal fibers may be used alone or in combinations. The determinant for the selection metal fiber is dependent on the properties desired in the composite material or the shaped article made therefrom. One useful fiber comprises a glass fiber known by the designations: A, C, D, E, Zero Boron E, ECR, AR, R, S, S-2, N, and the like. Generally, any glass that can be made into fibers either by drawing processes used for making reinforcement fibers or spinning processes used for making thermal insulation fibers. Such fiber is typically used as a length of about 0.8-100 mm often about 2-100 mm, a diameter about 0.8-100 microns and an aspect ratio (length divided by diameter) greater than 90 or about 100 to 1500.

These commercially available fibers are often combined with a sizing coating. Such coatings cause the otherwise ionically neutral glass fibers to form and remain in bundles or fiber aggregates. Sizing coatings are applied during manufacture before gathering. Sizings can be lubricants, protective, or reactive couplers but do not contribute to the properties of a composite using an interfacial modifier coating on the fiber surface.

A large variety of polymer and copolymer materials, such as thermoplastic or thermoset polymers, can be used in the composite materials used in the siding member. In some components, such as a nailing flange or support materials, a polymer can be used without fiber or particulate. We have found that polymer materials useful in the composite include both condensation polymeric materials and addition or vinyl polymeric materials. Vinyl polymers are typically manufactured by the polymerization of monomers having an ethylenically unsaturated olefinic group. Condensation polymers are typically prepared by a condensation polymerization reaction which is typically considered to be a stepwise chemical reaction in which two or more molecules combined, often but not necessarily accompanied by the separation of water or some other simple, typically volatile substance. Such polymers can be formed in a process called polycondensation. The typical polymer has a density of at least 0.85 gm-cm⁻³, however, polymers having a density of greater than 0.96 are useful to enhance overall product density. A polymer density is often up to 1.7 or up to 2 gm-cm⁻³ or can be about 1.5 to 1.95 gm-cm⁻³.

Vinyl polymers include polyacrylonitrile; polymer of alpha-olefins such as ethylene, propylene, etc.; polymers of chlorinated monomers such as vinyl chloride, vinylidene chloride, acrylate monomers such as acrylic acid, methyl acrylate, methyl methacrylate, acrylamide, hydroxyethyl acrylate, and others; styrenic monomers such as styrene, alpha-methyl styrene, vinyl toluene, etc.; vinyl acetate; and other commonly available ethylenically unsaturated monomer compositions. Examples include polyethylene, polypropylene, polybutylene, acrylonitrile-butadiene-styrene (ABS), polybutylene copolymers, polyacetal resins, polyacrylic resins, homopolymers or copolymers comprising vinyl chloride, vinylidene chloride, fluorocarbon copolymers, etc.

Condensation polymers include nylon, phenoxy resins, polyarylether such as polyphenylether, polyphenylsulfide materials; polycarbonate materials, chlorinated polyether resins, polyethersulfone resins, polyphenylene oxide resins, polysulfone resins, polyimide resins, thermoplastic urethane elastomers and many other resin materials. Condensation polymers that can be used in the composite materials include polyamides, polyamide-imide polymers, polyarylsulfones, polycarbonate, polybutylene terephthalate, polybutylene naphthalate, polyetherimides, polyether sulfones, polyethylene terephthalate, thermoplastic polyamides, polyphenylene ether blends, polyphenylene sulfide, polysulfones, thermoplastic polyurethanes and others. Preferred condensation engineering polymers include polycarbonate materials, polyphenyleneoxide materials, and polyester materials including polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate and polybutylene naphthalate materials.

Polymer blends or polymer alloys can be useful in manufacturing the claimed pellet or linear extrudate. Such alloys typically comprise two miscible polymers blended to form a uniform composition. Scientific and commercial progress in the area of polymer blends has led to the realization that important physical property improvements can be made not by developing new polymer material but by forming miscible polymer blends or alloys. A polymer alloy at equilibrium comprises a mixture of two amorphous polymers existing as a single phase of intimately mixed segments of the two macro molecular components. Miscible amorphous polymers form glasses upon sufficient cooling and a homogeneous or miscible polymer blend exhibits a single, composition dependent glass transition temperature (T_(g)). Immiscible or non-alloyed blend of polymers typically displays two or more glass transition temperatures associated with immiscible polymer phases. In the simplest cases, the properties of polymer alloys reflect a composition-weighted average of properties possessed by the components. In general, however, the property dependence on composition varies in a complex way with a particular property, the nature of the components (glassy, rubbery or semi-crystalline), the thermodynamic state of the blend, and its mechanical state whether molecules and phases are oriented.

The primary requirement for the substantially thermoplastic polymer material is that it retains sufficient thermoplastic properties such as viscosity and stability, to permit melt blending with a fiber, permit formation of linear extrudate pellets when needed, and to permit the composition material or pellet to be extruded or injection molded in a conventional thermoplastic process forming the useful product. Engineering polymer and polymer alloys are available from a number of manufacturers including Dyneon LLC, B.F. Goodrich, G.E., Dow, and duPont.

In the past, materials that are characterized, as “composite” have merely comprised a polymer filled with particulate with little or no van der Waals' interaction between the particulate filler material. The interaction between the selection of fiber size distribution and interfacially modified fiber enables the fiber to achieve an intermolecular distance that creates a substantial van der Waals' bond strength. The prior art materials having little viscoelastic properties, do not achieve a true composite structure.

The benefit of interfacial modification on a fully coated particle or fiber is independent of overall morphology. The current upper limit constraint of the aspect ratio (long fibers) is associated with challenges of successful dispersion of fibers within laboratory compounding equipment without significantly damaging the high aspect ratio fibers. Furthermore, inherent rheological challenges are associated with high aspect ratio fibers. With proper engineering, the ability to successfully compound and produce interfacially modified fibers of fiber fragments with aspect ratio more than 20 often in excess of 100, 200 or more is provided.

For composites containing high volumetric percent loading or loading fractions of fibers, the rheological behavior of the highly packed composites depends on the characteristics of the contact points between the fibers and the distance between fibers. When forming composites with polymeric volumes approximately equal to the excluded volume of the discontinuous phase, inter-fiber interaction dominates the behavior of the material. Fibers contact one another and the combination of interacting sharp edges, soft surfaces (resulting in gouging) and the friction between the surfaces prevent further or optimal packing. Interfacial modifying chemistries are capable of altering the surface of the fiber by coordination bonding, Van der Waals forces, or a combination of all three. The surface of the interfacially modified fiber behaves as a fiber formed of the non-reacted end or non-reacting end of the interfacial modifier. The coating of the interfacial modifier improves particle wetting by the polymer and as a result improves the physical association of the fiber and polymer in the formed composite leading to improved physical properties including, but not limited to, increased tensile and flexural strength, increased tensile and flexural modulus, improved notched IZOD impact and reduced coefficient of thermal expansion. In the melt, the interfacial modified coating on the fiber reduces the friction between fibers thereby preventing gouging and allowing for greater freedom of movement between fibers in contrast to fibers that have not been coated with interfacial modifier chemistry. As a result, the composite can be thermoplastically processed at greater productivity and at conditions of reduced temperature and pressure severity. The process and physical property benefits of utilizing the coated fibers in the acceptable fiber morphology index range does not become evident until packing to a significant proportion of the maximum packing fraction; this value is typically greater than approximately 40, 50, 60, 70, 80, 90, 92 or 95 volume or weight % of the fiber phase in the composite.

In a composite, the fiber is usually stronger and stiffer than the polymer matrix, and gives the composite its designed structural or shaped article properties. The matrix holds the fiber in an orderly high-density pattern. Because the fibers are usually discontinuous, the matrix also helps to transfer load among the metal, non-metal, inorganic, synthetic, natural, or mineral fibers. Processing can aid in the mixing and filling of the various fibers. To aid in the mixture, an interfacial modifier can help to overcome the forces that prevent the matrix from forming a substantially continuous phase of the composite. The tunable composite properties arise from the intimate association of the fiber and the polymer obtained using careful polymer processing and manufacture. We believe an interfacial modifier (IM) is an organic material that provides an exterior coating on the fiber promoting the close association of polymer and fiber but without covalent attachment or bonding of polymer to fiber or fiber to fiber.

Typically, the composite materials can be manufactured using melt processing and are also utilized in product formation using melt processing. A typical thermoplastic polymer material, is combined with IM coated fiber and processed until the material attains (e.g.) a uniform density (if density is the characteristic used as a determinant). Alternatively, in the manufacture of the material, the fiber or the thermoplastic polymer may be blended with interfacial modification agents and the modified materials can then be melt processed into the material. Once the material attains a sufficient property, such as, for example, density, the material can be extruded into a product or into a raw material in the form of a pellet, chip, wafer, preform or other easily processed material using conventional processing techniques.

In the manufacture of useful products, the manufactured composite can be obtained in appropriate amounts, subjected to heat and pressure, for example, in an extruder useful for 3D printing (additive manufacturing), or injection molding equipment and then formed into an appropriate shape having the correct amount of component polymer and fiber materials in the appropriate physical configuration. In the appropriate product design, during composite manufacture or during product or article manufacture, a pigment or other dye material can be added to the processing equipment. One advantage of this material is that an inorganic dye or pigment can be co-processed resulting in a material that needs no exterior painting or coating to obtain an attractive, functional, or decorative appearance. The pigments can be included in the polymer blend, can be uniformly distributed throughout the material and can result in a surface that cannot chip, scar or lose its decorative appearance. One particularly important pigment material comprises titanium dioxide (TiO₂). This material is non-toxic, is a bright white particulate that can be easily combined with the fiber and/or polymer composites to enhance the novel characteristics of the composite material and to provide a white hue to the ultimate composite material.

The manufacture of the composite materials depends on good manufacturing technique. The fiber is initially treated with an interfacial modifier by contacting the fiber with the modifier in the form of a solution of interfacial modifier on the fiber with blending and drying carefully to ensure uniform particulate or fiber coating. Interfacial modifier can also be added to fibers in bulk blending operations using high intensity Littleford or Henschel blenders. Alternatively, twin cone mixers can be followed by drying or direct addition to a screw compounding device. Interfacial modifiers may also be combined with the particulate and or fiber in aprotic solvent such as toluene, tetrahydrofuran, mineral spirits or other such known solvents.

The composite materials having the desired physical properties can be manufactured as follows. In an embodiment, the surface of the fiber is initially prepared, the interfacial modifier coats the fiber, and the resulting fiber coated product is isolated and then combined with the continuous polymer phase to affect an immiscible dispersion or association between the fiber and the polymer. Once the composite material is compounded or prepared, it is then thermoplastically formed into the desired shape of the end use article. Solution processing is an alternative that provides solvent recovery during materials processing.

The materials can also be dry-blended without solvent. Blending systems such as ribbon blenders obtained from Drais Systems, high-density drive blenders available from Littleford Brothers and Henschel are possible. Further melt blending using Banberry, other single screw or twin-screw compounders is also useful. When the materials are processed as a plastisol or organosol with solvent, liquid ingredients are generally charged to a processing unit first, followed by polymer, fiber and other components if needed followed by rapid agitation. Once all materials are added a vacuum can be applied to remove residual air and solvent, and mixing is continued until the composite product is uniform and high in density.

Dry blending is generally preferred due to advantages in cost. However certain embodiments can be compositionally unstable due to differences in fiber size. In dry blending processes, the composite can be made by first introducing the polymer, combining the polymer stabilizers, if necessary, at a temperature from about ambient to about 60° C. with the polymer, blending a fiber with the stabilized polymer, blending other process aids, interfacial modifier, colorants, indicators or lubricants followed by mixing in hot mix, transfer to storage, packaging or end use manufacture.

Interfacially modified materials can be made with solvent techniques that use an effective amount of solvent to initiate formation of a composite. When interfacial treatment is substantially complete, the solvent can be stripped.

Any adhesive that can maintain an adequate mechanically sufficient bond to insure a stable installation of the siding member can be used. The adhesive also needs to provide some substantial shear flexibility to obtain coefficient of thermal expansion capacity. Both hot melt and thermoset adhesives can be used with the required flexibility in the shear mode.

A pressure-sensitive adhesive comprises a layer of a pressure-sensitive adhesive and an optional release liner providing a release surface for the adhesive. Permanent pressure-sensitive adhesives are adhesives which have a level of adhesion which does not allow the removal from the substrate to which it has been applied without considerable damage the adhesive or the installation. The adhesion of removable pressure-sensitive adhesives is considerably lower, allowing removal of the siding member without damage to adhesive or member even after a protracted period.

Three modes of manufacture are contemplated. A layer of adhesive can be attached to the adhesive attachment surface of the support. With care the adhesive can be maintained without any additional protection. A layer of adhesive can be attached to the adhesive attachment surface of the support and the release liner can be attached thereto. A web of release liner can be coated with a removable pressure-sensitive adhesive, which is the attached to the support.

The construction comprises a siding member support with a layer of a permanent pressure-sensitive adhesive which is in turn in contact with a layer of a removable pressure-sensitive adhesive. The removable pressure-sensitive adhesive is in turn in contact with either a release surface of a release liner or a release surface on the opposed surface of the backing.

The pressure-sensitive adhesives employed in the installation may be any hot melt, emulsion, pressure-sensitive adhesives that can form a mechanically stable bond between the support and siding member. To obtain the desired thermal properties of the finished installation the adhesive must display sufficient bond strength to maintain the siding in place but still retain sufficient viscoelastic nature to permit the siding member to expand and contract with changing temperatures.

DETAILED DESCRIPTION OF THE DRAWINGS

The claimed structures are illustrated by the following Figures. The particular examples, materials, amounts, and procedures are to be interpreted broadly in accordance with the scope and spirit of the disclosure as set forth herein. The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings. An embodiment of the siding system of this disclosure is represented in the following figures, which should not be used as limiting to the scope of the claims.

FIGS. 1 and 2 show a plan view and a reverse view of the butt joint support 100 and adhesive attachment surface 109 and adhesive 111 supporting the siding member (not shown) for installation at a rough surface 906 (not shown) construction location.

Both the butt joint support 100 and corner joint support 200 are configured to be attached to external rough surface 906 (not shown) commonly conventional sheathing in both commercial and residential construction using a planar installation flange 101 and an angled corner installation flange 201 and fastener 113 attached via the fastener aperture 108.

In somewhat greater detail, FIG. 1 shows a butt joint support 100. The system contains a planar installation flange 101 that can contain a fastener aperture 108. Installed on the installation flange 101 is a tapered mounting for butt joint surface 103 for the butt joint support 100. The tapered butt joint mounting surface 103 has a tapered adhesive attachment surface 109. The angled attachment or installation surface has a tapered aspect that is embodied in a reduced thickness butt joint edge 106 that tapers down to a thickness of less than 1 to 2 millimeters and a full thickness butt joint surface 107 that has a thickness measured from the rough surface for attachment to the full thickness butt joint surface 107 that is greater than 3 millimeters. The taper includes an angle α (alpha), FIG. 2, that ensures that the installed siding unit has an appropriate angle after installation to shed water from the siding member.

Similarly, FIG. 2 shows the reverse side 105 of the planar installation flange 101 and the reverse side of the tapered mounting for the butt joint 103 a with angle α.

FIGS. 3 and 4 show a plan view and a reverse view of the corner joint support 200 for the siding member 130 (not shown). The corner joint support has an adhesive surface 202 for adhering the siding member 130 to the corner joint support 200. FIGS. 3 and 4 show a planar view and a reverse view of the corner joint support 200. The corner joint installation has an angled corner installation flange 201, a fastener aperture 108, and a tapered adhesive installation surface for the corner joint 104. The tapered installation body that includes an installation surface has an included angle that is congruent to the included angle of the reverse surface 205 of the angled corner installation flange 201 and the angle β of the rough sheathing. The tapered installation body for the corner joint 104 similarly has a tapered adhesive installation surface 202 and a reduced thickness corner joint edge 206 and a full thickness corner joint edge 207.

FIG. 4 shows the reverse view 200 a of the corner joint support 200 having the angled installation flange 201, the fastener aperture 108, the tapered mounting for corner joint 104, and the reverse surface of the tapered mounting of the corner joint support 103 b and the reverse of the angled installation flange 205.

FIG. 5 shows the installation of the siding member supported by the butt joint support 500 of the siding member 900 on the butt joint support 100. The butt joint support 100 includes the tapered mounting for butt joint surface 103 that can include the adhesive attachment. The siding member 900 contains a substantially planar or decorative exterior surface 901 for the exterior textured or planar surface of the siding member 901 and nailing flange 902 that contains a complimentary nailing flange installation channel 907 for mechanically accepting the J-form drip edge 903 into assembled courses and an associated J-form drip edge installation structure 903 on the opposite edge of the siding member 900.

FIG. 6 shows the installation of the siding member supported by the corner support 600 of the siding member 900 on the corner joint support 200. The corner joint support 200 contains the corner flange 201, the tapered installation body for mounting the corner joint support 104. The siding member 900 contains the exterior textured or planar surface of the siding member 901, the nailing flange 902 and the complimentary J-form drip edge overlap joint structure 903.

FIG. 7 is a side view 700 of the butt joint support 100 for the siding member. The butt joint support 100 shows the tapered installation surface for the butt joint 103 which includes an angle alpha (α), which is formed by the taper in the installation surface resulting from the reduced thickness edge 106 extending to the full thickness joint edge 107 the butt joint support angle α (alpha) ranges from about 1, 2, 3, 4, or about 5 degrees.

FIG. 8 shows a side view 800 of the corner joint support 200 including the tapered adhesive installation surface for the corner joint 202 with the tapered mounting for the corner joint 104 having a reduced thickness corner joint edge 206 and the full thickness corner joint edge 207 resulting in an included installation angle alpha in the tapered surface of the corner joint. Such angle α (alpha) can range from any of about 1°, 2°, 3°, 4°, 5°, 6°, 7°, 8°, 9° to about 10°.

FIG. 9 shows an isometric view of the siding member 900. Siding member 900 contains an exterior textured or planar surface 901 of the siding member 900. The siding member 900 additionally contains a nailing flange 902 and the complimentary J-form drip edge joint structure 903. The nailing flange 902 additionally contains a complementary nailing flange installation channel 907, which cooperates in a multi-course installation of the siding member 900. In the installation of a multi-course installation of siding member 900 the drip edge J-form joint structure 903 interacts with the complimentary nailing flange installation channel 907 to form a mechanically and structurally stable multi-course siding installation. In siding member 900 the nailing flange 902 is joined to the exterior planar surface 901 at the joint 905 between the nailing flange and the planar siding surface

FIG. 10 shows a side view of the installation 1000 of two course 900 a and 900 b of the siding member 901. The siding installation 1000 is placed on rough surface 906. The siding course 900 b is installed on the rough surface 906, followed by the second course 900 a using the interaction of the channel 907 and insertion edge of J-form portion drip edge 131 of J-form edge structure 903 for insertion into channel 907. The dimensions and design of the channel 907, once fixed in place, aids in installation and can friction fit/hold the next course in place for installation of fasteners.

FIG. 11 shows a detail of installation 1000 of FIG. 10 with the interaction of the nailing flange joinery aspect and the J-form joinery aspect in a stable joint. J-form joint structure 903 with insertion 131 interacts with the complimentary nailing flange installation channel 907 to form a mechanically stable multi-course siding installation. A mechanically stable joint between a first siding member installation and a second siding member installation 900 a and 900 b is achieved. The siding member has a thickness ti of any of about 0.75, 1.0, 1.5, 2.0, 2.5, 3.0, to 3.5 mm.

FIG. 12 shows a side view of the corner installation. Corner support 200 is installed on rough surface 906. Support 200 has installation flange 201 fixed in place with fasteners 113. Corner support 200 has a tapered surface 104 with adhesive 111 and release liner 112. Adhesive 111 can be used to fix siding member corner joint 904 on the support. Also shown is a first installed course using fastener apertures 102.

FIG. 13 shows a siding member aspect. The siding member 130 has a J-form edge structure 132 with drip edge 903 with insertion edge 131 that is formed in the siding for the nailing flange installation channel 907. The siding member 130 has a nailing flange with nailing surfaces 909 or 909(a), a siding member channel shaped support 908 and the J-form edge 131 installation channel 907.

FIG. 14 shows an expanded view of the nailing flange 902 from FIG. 13. The flange 140 has nailing surface 909 or 909(a), a curved installation support member channel shaped support 908 and the nailing flange installation channel 907 for the insert 131. Channel shaped support 908 is a curved support member with a siding support surface 911 that can be substantially cylindrical or partially cylindrical member with a diameter d₁ of about 3, 5, 7, 9 to 11 mm. The support can have a height h₁ of 3, 5, 7, to 9 mm that extends from the edge of the member channel shaped support surface 908 to the nailing surface 909. The height h₁ and resiliency of the member channel shaped support surface 908 holds the siding member in correct orientation. Curved installation channel 907 can be cylindrical or substantially cylindrical with a Channel curved surface 910 and a tabbed edge 912 that aids in insertion of the J-form edge. The cylindrical channel can have a diameter d₂ of any of 4, 6, 8, to 10 mm and a channel gap installation height h₂ from the inside of tabbed edge 912 to flange portion 913 of any of about 1, 2, 3 to 4 mm that can hold the insert 131 in place during installation. The correct height can hold the edge 131 as a friction fit or hold.

FIG. 15 shows a side view of a cooperative installation of two courses of the siding members in a first course and a second course of the siding members. The insertion edge 131 that extends from the J-form edge 132 of the siding member 130 is fixed and held in the nailing flange installation channel 907. Siding member 130 is supported by curved member channel shaped support 908. The height h₁ and resiliency of the member channel shaped support 908 holds the siding member in correct orientation. Curved installation channel 907 can be cylindrical or substantially cylindrical with a Channel curved surface 910 and a channel tabbed edge 912 that aids in insertion of the J-form edge. The cylindrical channel can have a diameter d₂ of any of 4, 5, 6, 7, 8, 9, 10, 11 to 12 mm and a height h₂ from the inside of channel tabbed edge 912 to flange portion 913 of any of about 1, 2, 3, to 4 mm that can hold the insert 131 in place during installation.

FIG. 16 shows a plan view of an installation of the siding member 130 with an installation support 140. The J-form (not seen) drip edge 903 of the siding member is inserted into the nailing flange channel 907, which holds the siding member in place in the installation. The siding member 130 is also supported and its angle, α, is maintained by the channel shaped support surface 908 and installation channel 907. The installation support 140 can be installed on a rough surface 906 by fasteners placed thorough the nailing surface(s) 909 or 909(a) that can contain optional fastener apertures (not shown).

Numerical Article Structure Designation Butt joint support 100 Corner joint support 200 Reverse view 200a Planar installation flange 101 Angled corner installation flange 201 Fastener aperture 108 Tapered mounting 103 for Butt joint 103a Fastener 113 Tapered installation body for 104 mounting corner joint Tapered adhesive installation 202 surface for corner joint Reverse surface for butt joint 105 support installation flange Reverse surface for corner joint 103b support Reduced thickness Butt Joint edge 106 Full thickness Butt joint 107 Tapered adhesive attachment 109 surface for butt joint Angled Installation Flange 205 (reverse side) Reduced thickness Corner 206 Joint edge Full thickness Corner joint edge 207 Butt joint support for siding 500 member Rough Surface (typically rough 906 siding or sheathing materials) Siding butt edge 904 Nailing Flange 902 Drip edge with J-form joint edge 903 Siding member supported by 600 corner support Side view of the butt joint support 700 Side view of corner joint support 800 Siding Member 900a/b/c Exterior textured or planar surface 901 of the siding member nailing flange installation Channel 907 Joint between flange and planar 905 siding surface Siding support as a channel 908 shaped support surface Nailing surface 909 909a Channel curved surface 910 Support curved surface 911 Channel tabbed edge 912 Support diameter d ₁ Channel diameter d ₂ Siding support height h ₁ Channel installation gap height h ₂ Nailing flange fastener aperture 102 Taper angle α Corner angle (congruent to rough β installation or sheathing surfaces) Adhesive 111 Release liner 112 Siding member with nailing flange 130 installation channel and support Insertion edge of J-form portion 131 for insertion into installation channel J-form structure 132

The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein and are not meant to limit the scope of the present disclosure.

As used in this specification and the appended claims, the term “or” is generally employed in its inclusive sense including “and/or” unless the content clearly dictates otherwise.

The words “preferred” and “preferably” refer to embodiments of the disclosure that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure.

The terms “comprises” and variations thereof do not have a limiting meaning where these terms appear in the description and claims.

“Include,” “including,” or like terms means encompassing but not limited to, that is, including and not exclusive.

The term “revealed surface” means the surface of the siding member that can be viewed after sufficient courses of the siding member are installed and cover a rough surface.

The term “installation orientation” means the positioning of the siding member(s) 130 and edge 904 and the butt joint support 100 and the corner joint support 200 when installed on a construction locus. The siding member(s) are installed with the major length dimension in the horizontal direction (roof line above and substantially parallel thereto, with foundation below) and with the nailing flange 902 installed on the top edge of the siding member. The term “installation orientation” means the positioning of the butt joint support 100 is installed with the major length dimension of the adhesive surface 109 parallel and supporting the edge 904 of the siding member. The term “installation orientation” means the positioning of the corner joint support 200 is installed with the major length dimension of the adhesion surface 202 parallel and supporting the edge 904 of the siding member.

The term “congruent angle means that the angles are substantially the same and differ less than ±5°.

The complete disclosure of all patents, patent applications, and publications cited herein are incorporated by reference. If any inconsistency exists between the disclosure of the present application and the disclosure(s) of any document incorporated herein by reference, the disclosure of the present application shall govern. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. The disclosure is not to be limited to the exact details shown and described, for variations obvious to one skilled in the art will be included within the disclosure defined by the claims.

Unless otherwise indicated, all numbers expressing quantities of components, molecular weights, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated to the contrary, the numerical parameters set forth in the specification and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. All numerical values, however, inherently contain a range necessarily resulting from the standard deviation found in their respective testing measurements.

All headings are for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified.

While the above specification shows an enabling disclosure of the composite technology of the disclosure, other embodiments may be made without departing from the spirit and scope of the claimed technology. Accordingly, the disclosed technology is embodied in the claims hereinafter appended. While the above specification shows an enabling disclosure of the composite technology of the system, other embodiments of the system components may be made without departing from the spirit and scope of the claimed subject matter. 

1-18. (canceled)
 19. A vinyl siding installation on a rough surface, the installation comprising: (i) at least two vinyl siding members in a butt joint relationship; and (ii) a support for the butt joint, the support having a planar base installed and in contact with the rough surface; wherein the support is tapered at an angle that ranges from about one to about 10° relative to the rough surface.
 20. The installation of claim 19 wherein the support comprises a contact surface comprising an adhesive layer.
 21. The installation of claim 20 wherein the adhesive layer comprises a release liner.
 22. The installation of claim 19 comprising a corner support for a corner butt joint wherein the support includes two support surfaces positioned at an angle of about 90°±5° that is congruent to a corner in the rough surface.
 23. The installation of claim 22 wherein each of the two surfaces have an adhesive layer.
 24. A installation of claim 19 and a member comprising a substantially planar siding member having a width of at least about 3 cm, a J-form drip edge, a nailing flange, and an installation channel wherein the J-form drip edge of a first member can form an installation joint with the installation channel of a second member.
 25. The installation of claim 19 wherein the rough surface is a vertical surface.
 26. The installation of claim 19 wherein the vinyl siding member has two or more nailing apertures.
 27. The installation of claim 19 wherein the vinyl siding member has an installation-channel adjacent to mechanically accept the J-form drip edge.
 28. The installation of claim 19 wherein the planar base has two or more nailing apertures. 